Disposable absorbent article having elasticized outer leg cuff

ABSTRACT

A disposable absorbent article having an elasticized outer leg cuff is disclosed. The disposable absorbent article comprises a liquid pervious topsheet, a liquid impervious backsheet, an absorbent core disposed therebetween, and a side flap extending laterally outwardly from the absorbent core. The absorbent article further comprises an elasticized outer leg cuff. The elasticized outer leg cuff is disposed adjacent to the longitudinal side edge in the crotch region and has a base and a gasket cuff supported by the base at a joint of the base to the gasket cuff. The gasket cuff is provided with an elastic material and has an inner cuff extending laterally inwardly from the joint and an outer cuff extending laterally outwardly from the joint. The gasket cuff is formed by folding the distal flap at least twice laterally inwardly toward the longitudinal centerline of the absorbent article.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.60/342,938, filed Dec. 21, 2001.

TECHNICAL FIELD

The present invention relates to a disposable absorbent article havingan elasticized outer leg cuff. More specifically, the present inventionrelates to a disposable absorbent article having an elasticized outerleg cuff having a base and a gasket cuff supported by the base.

BACKGROUND

Disposable absorbent articles provided with an elasticized outer legcuff are well known. There are a number of ways to form an elasticizedouter leg cuff. The most common approach is to form the elasticizedouter leg cuff from an elastic member being enclosed in the continuoustopsheet and the backsheet which extends beyond the edges of theabsorbent core. These elasticized outer leg cuffs provide a gasketcuffing action about the legs of the wearer to maintain a seal about theleg and minimize gapping. A number of attempts have been made to furtherimprove an elasticized outer leg cuff to minimize leakage.

Japanese Patent Laid-open publication H04-12751 published on Jan. 17,1992 discloses an absorbent article comprising a flexible side flaplaterally outwardly extending from the longitudinal side edge of theabsorbent core and an elastic material disposed on the side flap. Theside flap is folded inwardly toward the absorbent core at a portionbetween the longitudinal side edge of the absorbent core and the insideedge of the elastic material to form a first folding portion, and isfolded laterally outwardly at a portion between the first foldingportion and the inside edge of the elastic material to form a secondfolding portion. The second folding portion is joined to the firstfolding portion in the crotch region. It is stated that the secondfolding portion provides a seal in the crotch region and a pocket formedby the first folding and the second folding portions contain bodyexudates. In this structure, however, the longitudinal side edge of theside flap extending outwardly defines the longitudinal side edge of theabsorbent article. Because the longitudinal side edge of the side flapis typically cut or trimmed, the wearer feels uncomfortableness when theside edge touches the wearer's skin. Further, such a side edge is soflexible that the side edge of the side flap folds inwardly toward theabsorbent core or cannot resist bunching. In addition, the side edgeformed by being cut or trimmed provides a poor appearance.

European Patent publication 0 346 477 published on Dec. 20, 1989discloses a disposable nappy comprising a means arranged on oppositesides in the crotch region to prevent leakage. The means comprises aflexible flap and one or more elastic parts. The flap comprises asupport section extending up from the nappy, an inner wing sectionextending inwardly from the support section, and an outer wing sectionextending outwardly from the support section, in order to provide aT-shaped cuff. This publication merely discloses utilization of aT-shaped sleeve formed by a single sheet for a disposable nappy withoutshowing how to form such a T-shaped sleeve by a cost effective mannerand a simple operation.

Based on the foregoing, there is a need for a disposable absorbentarticle comprising an elasticized outer leg cuff which has a tailoredouter edge. There is also a need for a disposable absorbent articlecomprising an elasticized outer leg cuff formed by a cost effectivemanner and a simple operation. None of the existing absorbent articlesprovides all of the advantages and benefits of the present invention.

SUMMARY

The present invention is directed to a disposable absorbent article. Thedisposable absorbent article has an inner surface, an outer surface, acrotch region, longitudinal side edges and lateral end edges. Thedisposable absorbent article comprises a liquid pervious topsheet, aliquid impervious backsheet, an absorbent core disposed therebetween,and a side flap extending laterally outwardly from the absorbent core.The side flap has a proximal flap and a distal flap. The absorbentarticle further comprises an elasticized outer leg cuff. The elasticizedouter leg cuff is disposed adjacent to the longitudinal side edge in thecrotch region and has a base and a gasket cuff supported by the base ata joint of the base to the gasket cuff. The gasket cuff is provided withan elastic material and has an inner cuff extending laterally inwardlyfrom the joint and an outer cuff extending laterally outwardly from thejoint. The base comprises the proximal flap. The gasket cuff comprisesthe distal flap. The gasket cuff is formed by folding the distal flap atleast twice laterally inwardly toward the longitudinal centerline of theabsorbent article. The gasket cuff and the base are joined at the jointpositioned between the inner cuff and the outer cuff.

These and other features, aspects, and advantages of the invention willbecome evident to those skilled in the art from a reading of the presentdisclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed that the presentinvention will be better understood from the following description ofpreferred embodiments taken in conjunction with the accompanyingdrawings in which:

FIG. 1 is a perspective view of the diaper of one embodiment of thepresent invention;

FIG. 2 is a cross-sectional view taken along the line II-II of FIG. 1;

FIG. 3 is a top plan view of the diaper of FIG. 1 in its flat-outconfiguration;

FIG. 4 is a first alternative embodiment of the side flap;

FIG. 5 is a second alternative embodiment of the side flap;

FIG. 6 is a third alternative embodiment of the side flap;

FIG. 7 is a top plan view showing the first step of forming theelasticized outer leg cuff;

FIG. 8 is a cross-sectional view taken along the line VIII-VIII of FIG.7;

FIG. 9 is a top plan view showing the second step of forming theelasticized outer leg cuff;

FIG. 10 is a cross-sectional view taken along the line X-X of FIG. 9;

FIG. 11 is a top plan view showing the third step of forming theelasticized outer leg cuff;

FIG. 12 is a cross-sectional view taken along the line XII-XII of FIG.11;

FIG. 13 is a top plan view of the diaper having the ear panel in itsflat-out configuration;

FIG. 14 is a first alternative embodiment of the gasket cuff;

FIG. 15 is a second alternative embodiment of the gasket cuff;

FIG. 16 is a third alternative embodiment of the gasket cuff;

FIGS. 17-20 are a cross-sectional view of a first alternative embodimentof forming the elasticized outer leg cuff;

FIG. 21 is a cross-sectional view of a second alternative embodiment offorming the elasticized outer leg cuff;

FIG. 22 is a perspective view of an alternative embodiment of thediaper; and

FIG. 23 is a top plan view of the diaper of FIG. 22 in its flat-outconfiguration.

DETAILED DESCRIPTION

As used herein, the term “absorbent article” refers to devices whichabsorb and contain body exudates, and more specifically, refers todevices which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. The term “disposable” is used herein to describe absorbentarticles which generally are not intended to be laundered or otherwiserestored or reused as an absorbent article (i.e., they are intended tobe discarded after a single use and, preferably, to be recycled,composted or otherwise disposed of in an environmentally compatiblemanner). As used herein, the term “disposed” is used to mean that anelement(s) of the diaper is formed (joined and positioned) in aparticular place or position as a unitary structure with other elementsof the diaper or as a separate element joined to another element of thediaper. As used herein, the term “joined” encompasses configurationswhereby an element is directly secured to another element by affixingthe element directly to the other element, and configurations whereby anelement is indirectly secured to another element by affixing the elementto intermediate member(s) which in turn are affixed to the otherelement.) As used herein, the term “diaper” refers to an absorbentarticle generally worn by infants and incontinent persons about thelower torso. The present invention is also applicable to other absorbentarticles such as incontinence briefs, incontinence undergarments,absorbent inserts, diaper holders and liners, feminine hygiene garments,and the like. The term “longitudinal”, as used herein, refers to a line,axis or direction in the plane of the absorbent article that isgenerally aligned with (e.g., approximately parallel to) a verticalplane which bisects a standing wearer into left and right body halveswhen the absorbent article is worn. The terms “transverse” or “lateral”used herein, are interchangeable, and refer to a line, axis or directionwhich lies within the plane of the absorbent article that is generallyperpendicular to the longitudinal direction.

FIG. 1 is a perspective view of the diaper 20 of one embodiment of thepresent invention. Referring to FIG. 2 showing a cross-sectional viewtaken along the line II-II of FIG. 1 and FIG. 3 showing a top plan viewof the diaper 20 of FIG. 1 in its flat-out configuration as well, thediaper 20 has an inner surface 26 facing the wearer, an opposite outersurface 28, longitudinal centerline L, and lateral centerline T. Thediaper 20 also has longitudinal side edges 22 run generally in thelongitudinal direction of the diaper and lateral end edges 24 runbetween the longitudinal side edges 22 generally in the lateraldirection of the diaper 20. The periphery of the diaper 20 is defined bythe longitudinal side edges 22 and the lateral end edges 24. The diaper20 further has a front waist region 36, a back waist region 38 and acrotch region 40 disposed between the front waist region 36 and the backwaist region 38.

The diaper 20 comprises a chassis 54 and an ear panel 48 joined to thechassis 54. The chassis 54 has a generally rectangle shape in itsflat-out configuration as shown in FIG. 3. The chassis 54 has lateralend edges 58 and longitudinal side edges 56. The lateral end edge 58 ofthe chassis 54 preferably defines the lateral end edge 24 of the diaper20. The longitudinal side edges 56 of the chassis 54 preferably definesthe longitudinal side edge 22 of the diaper 20 at least in the crotchregion 40. The chassis 54 comprises a liquid pervious topsheet 30; aliquid impervious backsheet 32; an absorbent core 34, which ispreferably positioned between at least a portion of the topsheet 30 andthe backsheet 32; and a side flap 44 extending laterally outwardly fromthe absorbent core 34. The side flap 44 has a proximal flap 74 and adistal flap 76. The chassis 54 further comprises an elasticized outerleg cuff 42 disposed adjacent to the longitudinal side edge 22 in thecrotch region 40. The elasticized outer leg cuff 42 has a base 68 and agasket cuff 70 supported by the base 68 at a joint 72 of the base 68 tothe gasket cuff 70. The gasket cuff 70 is provided with an elasticmaterial 46 and has an inner cuff 100 extending laterally inwardly fromthe joint 72 and an outer cuff 102 extending laterally outwardly fromthe joint 72. The chassis 54 shown in FIG. 1 also may comprise barrierleg cuffs 52 and an elastic waist feature (not shown in Figures). Theear panel 48 is joined adjacent to the longitudinal side edge 56 of thechassis 54 and joined to an element constituting the chassis 54 such asa topsheet, a backsheet, an absorbent core, an elasticized outer legcuff, a barrier leg cuff or combinations thereof by any known means suchas adhesives or heat and pressure attachment such that the ear panel 48extends laterally outwardly from the absorbent core 34. In theembodiment shown in FIG. 1, the ear panel 48 is joined to the backsheet32 by heat and pressure attachment. A closure member such as a fasteningtape 39 is provided to the longitudinal side edge of the ear panel 48.

The liquid pervious topsheet 30 is preferably positioned adjacent thebody-facing surface of the absorbent core 34 and may be joined theretoand/or to the backsheet 32 by any attachment means known in the art. Thetopsheet 30 is preferably compliant, soft feeling, and non-irritating tothe wearer's skin. Further, at least a portion of the topsheet 30 isliquid pervious, permitting liquid to readily penetrate through itsthickness. A suitable topsheet 30 may be manufactured from a wide rangeof materials, such as porous foams; reticulated foams; apertured plasticfilms; or woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers. Preferably, the topsheet30 is made of a hydrophobic material or is treated to be hydrophobic inorder to isolate the wearer's skin from liquids contained in theabsorbent core 34. If the topsheet 30 is made of a hydrophobic material,preferably at least the upper surface of the topsheet 30 is treated tobe hydrophilic so that liquids will transfer through the topsheet morerapidly.

The liquid impervious backsheet 32 is generally that portion of thediaper 20 positioned adjacent the garment-facing surface of theabsorbent core 34. Backsheet 32 prevents the exudates absorbed andcontained therein from soiling articles that may contact the diaper 20,such as bedsheets and undergarments. In preferred embodiments, thebacksheet 32 is impervious to liquids (e.g., urine) and comprises a thinplastic film such as a thermoplastic film having a thickness of about0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils). Suitable backsheetfilms include those manufactured by Tredegar Industries Inc. of TerreHaute, Ind. and sold under the trade names X15306, X10962, and X10964.Other suitable backsheet materials may include breathable materials thatpermit vapors to escape from the diaper 20 while still preventingexudates from passing through the backsheet 32. Exemplary breathablematerials may include materials such as woven webs, nonwoven webs,composite materials such as film-coated nonwoven webs, and microporousfilms such as manufactured by Mitsui Toatsu Co., of Japan under thedesignation ESPOIR NO and by EXXON Chemical Co., of Bay City, Tex.,under the designation EXXAIRE. Suitable breathable composite materialscomprising polymer blends are available from Clopay Corporation,Cincinnati, Ohio under the name HYTREL blend P18-3097.

The absorbent core 34 may comprise any absorbent material that isgenerally compressible, conformable, non-irritating to the wearer'sskin, and capable of absorbing and retaining liquids such as urine andother certain body exudates. The absorbent core 34 has longitudinal sideedges and end edges and can be manufactured in a wide variety of sizesand shapes (e.g., rectangular, hourglass, “T”-shaped, asymmetric, etc.)and may comprise a wide variety of liquid-absorbent materials commonlyused in disposable diapers and other absorbent articles such ascomminuted wood pulp, which is generally referred to as airfelt.Examples of other suitable absorbent materials include creped cellulosewadding; meltblown polymers, including coform; chemically stiffened,modified or cross-linked cellulosic fibers; tissue, including tissuewraps and tissue laminates; absorbent foams; absorbent sponges;superabsorbent polymers; absorbent gelling materials; or any other knownabsorbent material or combinations of materials. In any case all or aportion of the core may include slits which allow the core to formopenings when stretched into which fecal mater can flow. Theconfiguration and construction of the absorbent core 34 may also bevaried (e.g., the absorbent core(s) or other absorbent structure(s) mayhave varying caliper zones, a hydrophilic gradient, a superabsorbentgradient, or lower average density and lower average basis weightacquisition zones; or may comprise one or more layers or structures).However, the total absorbent capacity of the absorbent core 34 should becompatible with the design loading and the intended use of the diaper20.

The barrier leg cuff 52 is joined adjacent the longitudinal side edges56 of the chassis 54. In the embodiment shown in FIG. 2, the barrier legcuff 52 is joined onto the topsheet 30 at the proximal edge 66 of thebarrier leg cuff 52 by any known means. Alternatively, the barrier legcuff 52 may be joined to the backsheet 32 without being joined to thetopsheet 30. The barrier leg cuff 52 may comprise any known materialssuch as a nonwoven material which may be liquid impervious and/orhydrophobic. The barrier leg cuff 52 has a lateral inner portion 62extending laterally inwardly from the proximal edge 66 and beingprovided with an elastic materials at the distal end of the lateralinner portion 62 to space the lateral inner portion 62 upwardly awayfrom the topsheet 30 to serve as a barrier to leakage of body exudates.The barrier leg cuff 52 also has a lateral outer portion 60 extendinglaterally outwardly from the proximal edge 66 and being joined onto thelateral extension of the topsheet 30 and the lateral extension of thebacksheet 32 in the embodiment shown in FIG. 2. The lateral outerportion 60 shown in FIG. 2 extends further laterally outwardly beyondboth the longitudinal side edge 31 of the topsheet 30 and thelongitudinal side edge 33 of the backsheet 34.

The side flap 44 shown in FIGS. 1, 2 and 3 is disposed adjacent thelongitudinal side edge 56 of the chassis 54 so as to extend laterallyoutwardly from the absorbent core 34 in the embodiment shown in FIG. 2.The side flap 44 is preferably formed with a material which is liquidimpervious and/or hydrophobic. The side flap 44 has a proximal flap 74which is laterally proximate to the absorbent core 34 and a distal flap76 which extends laterally outwardly from the proximal flap 74. Theproximal flap 74 and the distal flap 76 may be formed by an integralmaterial or alternatively may be formed by separate materials joined toeach other. The side flap 44 may be formed by a single layer ofmaterial, or two or more layers of material. In the embodiment shown inFIG. 2, a portion of the proximal flap 74 proximate to the proximal edge66 is formed by the lateral extension of the topsheet 30, the lateralextension of the backsheet 32 and the lateral outer portion 60. Aportion of the proximal flap 74 laterally outside thereof is formed bythe lateral extension of the backsheet 32 and the lateral outer portion60 of the barrier leg cuff 52. This configuration allows the proximalflap 74 to be liquid impervious because the liquid impervious backsheet32 extends into the proximal flap 74. In the embodiment, the distal flap76 is formed by only the lateral outer portion 60 of the barrier legcuff 52. It is preferable that a portion of the side flap comprising twoor more layers are joined throughout the coextensive area of the layersby any known means such as adhesives. This allows the longitudinal sideedge 33 of the backsheet 34 not to separate from the lateral outerportion 60 of the barrier leg cuff 52 and contributes to provide atailored outer edge of the diaper.

Many variations for forming the side flap are possible. In theembodiment shown in FIG. 2, the proximal flap 74 may be formed only bythe lateral outer portion 60 of the barrier leg cuff 52 without thelateral extension of the backsheet 32. When the barrier leg cuff 52 isformed by a hydrophobic and/or liquid impervious material, the proximalflap 74 may have a sufficient liquid impermeability even though there isno backsheet 32 extended thereinto. This design also allows the proximalflap 74 to be highly breathable and less bulky. In the embodiment shownin FIG. 2, the topsheet 30 may extend into the proximal flap 74 suchthat the topsheet 30 extends to the same extent as the backsheet 32.

Shown in FIGS. 4, 5, and 6 are an alternative embodiment of the sideflap 44. In the embodiment shown in FIG. 4, the barrier leg cuff iseliminated. Instead, a side flap sheet 240 is joined to the lateralextension of the topsheet 230 and the lateral extension of the backsheet232 to form the side flap 244. A portion of the proximal flap 274proximate to the absorbent core 234 is formed by the lateral extensionof the topsheet 230, the lateral extension of the backsheet 232 and theside flap sheet 240. A portion of the proximal flap 274 outside thereofis formed by the lateral extension of the backsheet 232 and the sideflap sheet 240. In the embodiment, the distal flap 276 is formed by onlythe side flap sheet 240. At least a portion of the side flap sheet 240forming the distal flap 276 or the entirety of the side flap sheet 240is preferably hydrophobic and/or liquid impervious. In the embodimentshown in FIG. 5, the lateral extension of the topsheet 330 extends intothe proximal flap 374 and the distal flap 376 to form the side flap 344.A portion of the proximal flap 374 proximate to the absorbent core 334is formed by the lateral extension of the topsheet 330, the lateralextension of the backsheet 332 and the lateral outer portion 360 of thebarrier leg cuff 352. A portion of the proximal flap 374 outside thereofis formed by the lateral extension of the backsheet 332 and the lateralextension of the topsheet 330. In the embodiment, the distal flap 376 isformed by only the lateral extension of the topsheet 330. At least aportion of the topsheet 330 forming the distal flap 376 is preferablyrendered to be hydrophobic and/or liquid impervious. In the embodimentshown in FIG. 6, the backsheet 432 comprises an outer nonwoven 424covering the liquid impervious backsheet film 425. The outer nonwoven424 extends into the proximal flap 474 and the distal flap 476 to formthe side flap 444. A portion of the proximal flap 474 proximate to theabsorbent core 434 is formed by the lateral extension of the topsheet430, the lateral extension of the backsheet film 425, the lateral outerportion 460 of the barrier leg cuff 452 and the outer nonwoven 424. Aportion of the proximal flap 474 outside thereof is formed by thelateral extension of the backsheet 432 and the outer nonwoven 424. Inthe embodiment, the distal flap 476 is formed by only the outer nonwoven424. At least a portion of the outer nonwoven 424 forming the distalflap 476 or the entirety of the outer nonwoven 424 is preferablyrendered to be hydrophobic and/or liquid impervious.

Further alternative embodiments of the side flap are possible. Forexample, the side flap may comprise any other material joined to thechassis 54 or may comprise any combination of an extension of thetopsheet, an extension of the backsheet, an extension of a barrier legcuff, and/or any other material. While the distal flap shown in FIGS. 4,5 and 6 is formed with only one layer of the material extending into thedistal flap, it may comprise two or more layers extending into thedistal flap. As explained hereinbelow, the distal flap is used to formthe elasticized outer leg cuff, a portion of which touches the skin ofthe wearer. Therefore, it is preferable that the surface of the distalflap which will touch the skin of the wearer comprises resilient,flexible and soft material such as a nonwoven or woven.

The elasticized outer leg cuff 42 shown in FIGS. 1, 2 and 3 comprisesthe side flap 44 and the elastic material 46. The outer leg cuff 42 is agenerally T-shaped cuff having a base 68 and a gasket cuff 70 supportedby the base 68 at a joint 72 of the base to the gasket cuff 70. The term“generally T-shaped” means that the base branches from the gasket cuffat the joint between the inner cuff and the outer cuff of the gasketcuff such that the base forms an angle with the inner cuff and an anglewith an outer cuff in a cross-sectional view when the diaper is in arelaxed configuration. Therefore, the base may form an angle of 90degree or an angle other than 90 degree with the inner cuff and theouter cuff. The base 68 comprises the proximal flap 74 and extendsbetween the longitudinal side edge of the absorbent core 34 and thejoint 72. The gasket cuff 70 comprises the distal flap 76 and disposedon the top of the base 68.

The gasket cuff 70 has an inner cuff 100 extending laterally inwardlyfrom the joint 72 and an outer cuff 102 extending laterally outwardlyfrom the joint 72 as shown in FIG. 2. The gasket cuff 70 is formed withthe distal flap 76 of the side flap 44 being folded at least twice alonga first folding line 78 and a second folding line 80 laterally inwardlytoward the longitudinal centerline L of the diaper 20 and is formed intoa thin flat sleeve-like shape in a cross-section having an innerlongitudinal edge 82, an outer longitudinal edge 84, a top gasket cuffsurface 86 and an opposite surface 88. The top gasket cuff surface 86has a generally flat surface in cross-section as shown in FIG. 2 whileit may have a degree of undulation in the longitudinal direction formedby the gather caused by the elastic material 46 as shown in FIG. 1. Thegasket cuff 70 may be formed into a different cross-section such ascircle, oval, U-shape, or V-shape while the thin flat shape ispreferable. In the embodiment shown in Figures, the first folding line78 and the second folding line 80 correspond to the inner longitudinaledge 82 and the outer longitudinal edge 84 of the gasket cuff 70,respectively. The opposite surface 88 of the gasket cuff 70 is joinedwith the base 68 at the joint 72 which is located between the inner cuff100 and the outer cuff 102 by any known means such as adhesives,preferably at the middle between the inner cuff 100 and the outer cuff102. The gasket cuff 70 is provided with the elastic material 46 such asa plurality of elastic strands, a single elastic belt or the like. Theelastic material 46 is encased into the thin sleeve-like space of thegasket cuff 70 and joined to the inner surface thereof. In theembodiment shown in FIG. 2, the elastic material 46 includes fourelastic strands. Two elastic strands are disposed along the inner andouter longitudinal edges 82 and 84 and the other two elastic strands aredisposed adjacent to the joint 72, preferably on the laterally oppositesides of the joint 72. Alternatively, the elastic strands 46 maycomprise two or more elastic strands or may comprise a single elasticbelt having a width extending between the inner and outer longitudinaledges 82 and 84. The elastic material 46 extends generally in the crotchregion 40 such that the elastic material 46 provides elasticity for thegasket cuff 70 and provides a gather to the gasket cuff 70 when thediaper 20 is relaxed as shown in FIG. 1. The elastic material 46 alsoprovides a force to stand the base 68 generally upwardly from theabsorbent core 34 as shown in FIG. 2. Thus, the combination of the base68 and the gasket cuff 70 provides a generally T-shaped cuff when theouter leg cuff 42 is in a relaxed configuration. It also provides achannel 90 between the opposite surface 88 of the inner cuff 100 and theinner surface of the base 68 to enhance containment properties of bodyexudates.

The gasket cuff 70 preferably has a lateral width to provide a goodsealing effect against the leakage of body exudates when the gasket cuff70 touches the skin of the wearer in use. The wide gasket cuff 70efficiently provides a wide skin contact area for a good sealing effect.However, such a wide gasket cuff may cause uncomfortableness to thewearer because of the wide skin contact area. Therefore, the gasket cuff70 may have the lateral width of between about 3 mm and about 50 mm,preferably between about 5 mm and about 30 mm, more preferably about 10mm and about 20 mm along the lateral centerline T at the crotch region40 of the diaper 20. The lateral width can be measured as the widthbetween the inner longitudinal edge 82 and the outer longitudinal edge84 of the gasket cuff 70. The gasket cuff 70 may have the same lateralwidth throughout its longitudinal length. However, the lateral width ofthe gasket cuff 70 may vary along the longitudinal length of the gasketcuff 70. For example, the gasket cuff 70 may have the lateral width atthe crotch region 40 greater than at the front and/or back waist region36, 38.

The base 68 preferably has a lateral width to provide a good containmentcharacteristics when the base 68 stands upwardly from the absorbent core34 as shown in FIG. 2. The base 68 may have the lateral width of betweenabout 10 mm and about 100 mm, preferably between about 20 mm and about80 mm, more preferably about 30 mm and about 70 mm along the lateralcenterline T at the crotch region 40 of the diaper 20. The lateral widthcan be measured as the width between the joint 72 and the longitudinalside edge of the absorbent core 34. The base 68 may have the samelateral width throughout its longitudinal length. However, the lateralwidth of the base 68 may vary along the longitudinal length of the base68. For example, the base 68 may have the lateral width at the crotchregion 49 greater than at the front and/or back waist region 36, 38.

FIGS. 7 to 12 show a process to form the elasticized outer leg cuff 42of FIGS. 1, 2 and 3 from the side flap 44 and the elastic material 46.In the embodiment shown in FIGS. 7 and 8, the side flap 44 ispreassembled by joining the topsheet 30, the backsheet 32 and thebarrier leg cuff 52 prior to forming the outer leg cuff 42. The sideflap 44 has the proximal flap 74 and the distal flap 76 which isvirtually separated by the point of the joint 72 in the embodiment shownin FIG. 8. The side flap 44 has a first surface 43 and a second surface45. The distal flap 76 has a first flap portion (first folded portion)73, a second flap portion (second folded portion) 75 and a third flapportion 77. The first flap portion 73 and the second flap portion 75 aredivided by a first folding line 78 shown by an imaginary line in FIG. 7.The second flap portion 75 and the third flap portion 77 are divided bya second folding line 80 shown by an imaginary line in FIG. 7. In theembodiment shown in FIGS. 7 and 8, the elastic materials 46 comprisingfour elastic strands are stretched and disposed on the first surface 43of the second flap portion 75 of the distal flap 76. The elastic strands46 are then joined thereto by any known means such as adhesives. Theelastic strands 46 extend in the region between the first folding line78 and the second folding line 80 in the crotch region 40. The elasticstrands 46 may extend into the front waist region 36 and/or the backwaist region 38. The first flap portion 73 has a lateral width to coverfour of the elastic strands 46 when the first flap portion 73 is foldedas explained hereinbelow and has the almost same lateral width as thesecond flap portion 75. The third flap portion 77 is almost half of thelateral width of the second flap portion 75. First cuff formingadhesives 116 are provided to join the first flap portion 73 to thesecond flap portion 75 adjacent to the lateral end edge 24 when thefirst flap portion 73 is folded onto the second flap portion 75.

The distal flap 76 of the side flap 44 is then folded once along thefirst folding line 78 adjacent the outermost elastic strands 47laterally inwardly toward the longitudinal centerline L of the diaper 20as shown in FIGS. 9 and 10. The first flap portion 73 of the distal flap76 is folded toward the side of the inner surface 26 of the diaper 20.The distal flap 76 sandwiches the four of elastic strands 46 between thefirst folded portion (first flap portion) 73 and the second flap portion75. When the elastic strands 46 are sandwiched, the elastic strands 46are preferably joined to the first surface 43 of the first foldedportion 73 and the second flap portion 75. A joint adhesive 92 isprovided on the second surface 45 of the first folded portion 73 to formthe joint 72 between the gasket cuff 70 and the base 68. The jointadhesive 92 is disposed as a continuous straight line between the firstfolding line 78 and the second folding line 80 in the configuration inwhich the gasket cuff 70 is assembled as shown in FIG. 2, preferably atthe middle therebetween such that the gasket cuff 70 and the base 68form a generally T-shaped cuff. In other words, the joint adhesive 92 isprovided at the middle between the first folding line 78 and thelongitudinal side edge 94 of the distal flap 76. In the embodiment shownin FIG. 9, the joint adhesive 92 extends continuously in thelongitudinal direction between the lateral end edges 58 of the chassis54. As far as the gasket cuff 70 and the base 68 form a generallyT-shaped cuff, the joint adhesive may take any shape such as a wavyline, or a dotted line, or any position. While the joint adhesive 92 isprovided only at the middle between the first folding line 78 and thelongitudinal side edge 94 of the distal flap 76 in the embodiment shownin FIGS. 9 and 10, the joint adhesive 92 may be provided between theposition of the joint adhesive 92 shown in FIG. 9 and 10 and thelongitudinal side edge 94 of the distal flap 76. The joint adhesive 92may be provided on the first folded portion 73 before or after thedistal flap 76 is folded into a configuration shown in FIGS. 9 and 10.Alternatively, the joint adhesive 92 may be provided on the position ofthe side flap 44 corresponding to the joint 72 as shown by a referencenumber 193 in FIG. 10. Second cuff forming adhesives 118 are provided tojoin the first flap portion 73 to the third flap portion 77 and aportion inside thereof adjacent to the lateral end edge 24 when thefirst flap portion 73 is joined onto third flap portion 77 and a portioninside thereof.

The distal flap 76 having the four elastic strands 46 sandwiched by thefirst flap portion 73 and the second flap portion 75 is then againfolded along the second folding line 80 adjacent the innermost elasticstrands 49 laterally inwardly toward the longitudinal centerline L ofthe diaper 20 as shown in FIGS. 11 and 12. The distal flap 76 is foldedtoward the side of the inner surface 26 of the diaper 20. The distalflap 76 encases the four of elastic strands 46 by the first foldedportion 73, the second folded 75, the first folding line 78 and thesecond folding line 80. The first folding line 78 and the second foldingline 80 correspond to the inner longitudinal edge 82 and the outerlongitudinal edge 84 of the gasket cuff 70, respectively. In theembodiment shown in FIG. 12, the first folded portion 73 has a lateralwidth such that the longitudinal side edge 94 of the distal flap 76 ishidden inside the gasket cuff 70. The joint adhesive 92 forms the joint72 between the gasket cuff 70 and the base 68, whereby the inner cuff100 and the outer cuff 102 are formed. In addition, it forms the gasketcuff 70 and the base 68 which constitute the outer leg cuff 42. Theouter leg cuff 42 is provided along the longitudinal side edge 56 of thechassis 54. The outer longitudinal edge 84 of the gasket cuff 70 definesthe longitudinal side edge 56 of the chassis 54. When the outer leg cuff42 is in a relaxed configuration, the outer leg cuff 42 has a generallyT-shaped configuration having a thin flat shaped gasket cuff 70 and thegenerally upwardly standing base 68.

The elasticized outer leg cuff 42 thus formed has several benefits. Thegasket cuff 70 of the outer leg cuff 42 formed into a thin flatsleeve-like shape and having a flat top gasket cuff surface 86 providesan effective gasket seal between the wearer's skin and the surface 86.The gasket cuff 70 is provided with a degree of stiffness by beingfolded at least twice while it is still gentle and soft to the skin ofthe wearer. Therefore, the sealing effect between the wearer's skin andthe surface 86 is enhanced. In addition, the gasket cuff 70 having adegree of stiffness prevents or at least reduce the outer longitudinaledge 84 of the gasket cuff 70 to be flipped over laterally inwardlytoward the longitudinal centerline L of the diaper 20. Therefore, theuser or wearer does not have to pay much attention to make sure whetheror not the gasket cuff is flipped over when the wearer wears the diaper20 and/or whether the gasket cuff 70 properly fits the wearer. Thegasket cuff 70 of the present invention has the outer longitudinal edge84 and the inner longitudinal edge 82 formed by folding the distal flap76 at least twice laterally inwardly toward the longitudinal centerlineL of the diaper 20. This not only provides a cost effective and simpleoperation for forming the gasket cuff 70, but also provides the gasketcuff 70 with a tailored appearance compared to the conventional outerleg cuff having exposed outer edges formed with cut or trimmed sideedges which give a poor appearance. When the gasket cuff 70 comprises anonwoven material, it also provides a soft and cloth like appearance tothe gasket cuff.

The ear panel 48 is provided adjacent the longitudinal side edge 56 ofthe chassis 54 to extend laterally outwardly from the absorbent core 34.The ear panel 48 may be joined to the chassis 54 before the gasket cuff70 of the outer leg cuff 42 is formed by folding the distal flap 76 ofthe side flap 44. However, when the ear panel 48 is joined to thechassis 54 prior to forming the outer leg cuff 42, the folding operationof the distal flap 76 requires a complicated operation to make sure thatthe folding operation of the distal flap 76 does not fold the ear panel48 together with the distal flap 76. Therefore, it is preferable thatthe ear panel 48 is joined to the chassis 54 after the outer leg cuff 42is formed. In other words, the gasket cuff 70 is preferably formed byfolding the distal flap 76 before the ear panel 48 and the gasket cuff70 are joined to each other through the elements constituting thechassis 54 such as a backsheet, a topsheet, and/or a barrier leg cuff.This allows easy and simple operation to fold the distal flap 76 sincethe ear panel 48 is not an obstacle to fold the distal flap 76 to formthe gasket cuff 70. Therefore, it is preferable that the chassis 54having the outer leg cuff 42 is first assembled and then the ear panel48 is joined to the chassis 54 as shown in FIG. 13.

The embodiment shown in FIGS. 1-3 is a so-called taped diaper having thefastening tape 39 to form the closure of the diaper. Alternatively, apair of the ear panels may be joined to the chassis at both the frontwaist region and the back waist region. The longitudinal side edges ofthe ear panels at the front waist region and at the back waist regionmay be joined by a seam such that the diaper forms a so-called pull-ondiaper having one waist opening and two leg openings.

Shown in FIG. 14 is an alternative embodiment of the gasket cuff of theelasticized outer leg cuff. In the embodiment of the gasket cuff 570shown in FIG. 14, the distal flap 576 may be folded once along the firstfolding line 578 adjacent the outermost elastic strands 547 to form thefirst folded portion 573. Then the distal flap 576 is folded again alongthe second folding line 580 adjacent the inner most elastic strands 549to form the second folded portion 575. The first folded portion 573 hasonly the; lateral width to cover the outermost elastic strand 547, butnot to cover four of the elastic strands. A portion of the distal flap576 adjacent the longitudinal side edge 594 is joined to the firstsurface 543 of the second folded portion 575. Alternatively, the firstfolded portion 573 may have the lateral width to cover the right twoelastic strands in FIG. 10, but not to cover the right three elasticstrands. The joint 572 is made by joining a portion of the first surface543 of the second folded portion 575 and a portion of the first surface543 along the inner longitudinal side edge of the third flap portion579.

FIG. 15 shows a further alternative embodiment of the gasket cuff of theelasticized outer leg cuff. In the embodiment of the gasket cuff 670shown in FIG. 15, the distal flap 676 may be folded once along the firstfolding line 678 adjacent the outermost elastic strands 647 to form thefirst folded portion 673. Then the distal flap 676 is folded again alongthe second folding line 680 adjacent the inner most elastic strands 649to form the second folded portion 675. The first folded portion 673 hasthe lateral width to cover four of the elastic strands shown in FIG. 15,to extend beyond the second folding line 680 and further to extendbeyond the joint 672. The longitudinal side edge 694 of the distal flap676 extending beyond the joint 672 in FIG. 15 may be joined to a portionof the proximal flap 674 by any known means such as adhesives.

FIG. 16 shows a further alternative embodiment of the gasket cuff of theelasticized outer leg cuff. In the embodiment of the gasket cuff 770shown in FIG. 16, the gasket cuff 770 is formed by folding the distalflap 776 three times laterally inwardly toward the longitudinalcenterline of the absorbent article. The gasket cuff 770 has the firstfolding portion (first flap portion) 773 between the longitudinal sideedge 794 and the first folding line 778, the second folding portion(second flap portion) 775 between the first folding line 778 and thesecond folding line 780, the third folding portion (third flap portion)777 between the second folding line 780 and the third folding line 781,and the fourth flap portion 779. In this embodiment, the first foldingline 778 and the third folding line 781 are generally coextensive. Thethird folding line 781 and the second folding line 780 correspond to theouter longitudinal edge 784 and the inner longitudinal edge 782 of thegasket cuff, respectively. Alternatively, the gasket cuff 770 may beformed by folding the distal flap more than four times laterallyinwardly toward the longitudinal centerline of the absorbent article.

FIGS. 17 to 20 show an alternative embodiment of a process to form theelasticized outer leg cuff. In the embodiment shown in FIGS. 17 to 20,the side flap 1044 is preassembled to have the generally sameconfiguration as that shown in FIG. 8. The side flap 1044 has theproximal flap 1074, the distal flap 1076, the first surface 1043 and thesecond surface 1045. The distal flap 1076 also has the first flapportion 1073, the second flap portion 1075 and the third flap portion1077. The elastic strands 1046 are disposed on and joined to the firstsurface 1043 of the second flap portion 1075. The distal flap 1076 isfolded once along the first folding line 1078 adjacent the outermostelastic strands 1047 laterally inwardly toward the longitudinalcenterline L of the diaper 20 as shown in FIG. 18. The first flapportion 1073 of the distal flap 1076 is folded toward the side of theinner surface 1026 of the diaper to sandwich the elastic strands 1046.In this configuration, the longitudinal side edge 1094 of the distalflap 1076 is preferably joined to the first surface 1043 by the adhesive1093. The distal flap 1076 is then again folded along the second foldingline 1080 adjacent the innermost elastic strands 1049 laterally inwardlytoward the longitudinal centerline L of the diaper as shown in FIG. 19.The distal flap 1076 is folded toward the side of 5 the outer surface1028 of the diaper in the embodiment shown in FIG. 19. In thisconfiguration, the second flap portion 1075 is joined to the third flapportion 1077 by the joint adhesive 1092. The distal flap 1076 is againfolded along the third folding line 1081 adjacent the joint adhesive1092 laterally inwardly toward the longitudinal centerline L of thediaper as shown in FIG. 20. The distal flap 1076 is folded toward theside of the inner surface 1026 of the diaper in the embodiment shown inFIG. 20. Thus, the gasket cuff 1070 and the base 1068 of the outer legcuff 1042 are formed.

FIG. 21 shows an alternative embodiment of one step of the process toform the elasticized outer leg cuff by the drawings shown in FIGS.17-20. After folding the distal flap 1073 once along the first foldingline 1078 adjacent the outermost elastic strands 1047 laterally inwardlytoward the longitudinal centerline L of the diaper as shown in FIG. 18,the distal flap may be folded again along the second folding line 2080laterally inwardly toward the longitudinal centerline L so as to befolded toward the side of the inner surface 1026 as shown in FIG. 21,instead of being folded toward the side of the outer surface 1028 asshown in FIG. 19. Then the distal flap 1073 is folded along the thirdfolding line 2081 laterally outwardly from the longitudinal centerline Lof the diaper 20. The joint adhesive 2092 is provided to form the gasketcuff 1070 and the base 1068 of the outer leg cuff 1042 as shown in FIG.20.

Further alternative embodiments are possible to form the elasticizedouter leg cuff. For example, the side flap may be assembled afterforming the gasket cuff of the elasticized outer leg cuff. The side flapof the embodiment shown in FIGS. 7-12 is preassembled by joining thetopsheet, the backsheet and the barrier leg cuff prior to forming theouter leg cuff. However, the gasket cuff may be separately formed byfolding the lateral outer portion of the barrier leg cuff, which willlater become the distal flap of the side flap, before the barrier legcuff is joined to other elements of the side flap. The barrier leg cuffhaving the gasket cuff thus formed may be then joined to other elementsforming the side flap such as a backsheet and/or a topsheet. In thisembodiment, the barrier leg cuff having the gasket cuff may be joined toa portion of the chassis such as a backsheet and/or a topsheet which hasbeen already provided with the ear panel or alternatively may be joinedto a portion of the chassis which has not yet been provided with the earpanel. In the latter case, the ear panel is joined to a portion of thechassis after the barrier leg cuff having the gasket cuff is joined tothe chassis. In either case, the gasket cuff is formed by folding thedistal flap of the side flap before the ear panel and the gasket cuffare joined to each other.

Alternatively, the barrier leg cuff may be first joined to the topsheetto form an assembly. The gasket cuff is then formed by folding thelateral outer portion of the barrier leg cuff of the assembly, whichwill later become the distal flap of the side flap. After that, theassembly having the gasket cuff may be joined to backsheet such that theabsorbent core is positioned between the topsheet and the backsheet. Inthese embodiments, the assembly having the gasket cuff may be joined toa portion of the backsheet which has been already provided with the earpanel or alternatively may be joined to a portion of the backsheet whichhas not yet been provided with the ear panel. In the latter case, theear panel is joined to a portion of the backsheet after the assemblyhaving the gasket cuff is joined to the backsheet. In either case, thegasket cuff is formed by folding the distal flap of the side flap beforethe ear panel and the gasket cuff are joined to each other.

Shown FIGS. 22 and 23 are further alternative embodiment of the presentinvention. The diaper 3020 has an inner surface 3026, an outer surface,a crotch region 3040, longitudinal side edges 3022, and lateral sideedges 3024. The diaper 3020 comprises a chassis 3054 and an ear panel3048 joined to the chassis 3054. The chassis 3054 has a liquid permeabletopsheet 3030, a liquid impermeable backsheet 3032, and an absorbentcore 3034. The chassis 3054 also comprises a side flap 3044 extendinglaterally outwardly from the absorbent core 3034 and having a proximalflap 3074 and a distal flap 3076. The ear panel 3048 has a fasteningtape 3039 to form a closure of the diaper 3020. The ear panel 3048 ofthe diaper 3020 is formed with an integral material constituting aportion of the chassis 3054 such as a backsheet 3032, and/or a topsheet3030. In the embodiment shown in FIG. 22, the ear panel 3048 is formedwith an integral extension of the backsheet 3032 (e.g., an extension ofa liquid impermeable film or an extension of an outer nonwoven coveringthe liquid impermeable film). Therefore, the backsheet 3032 of thediaper 3048 has a generally hourglass shape having a narrow crotchregion 3040. The backsheet 3048 also has the longitudinal side edge 3049in the crotch region 3040.

The elasticized outer leg cuff 3042 is disposed along the longitudinalside edge 3022 of the diaper 3020. The elasticized outer leg cuff 3042has the gasket cuff 3070 and the base 3068. The gasket cuff 3070 isformed by the distal flap 3076, more concretely the lateral outerportion 3060 of the barrier leg cuff 3052, by folding the distal flap3076 at least twice laterally inwardly toward the longitudinalcenterline of the diaper as explained hereinabove. The gasket cuff 3070and the base 3068 are joined at the joint (not shown in FIGS. 22 and 23)positioned between the inner cuff 3100 and the outer cuff 3102. In theembodiment shown in FIGS. 22 and 23, the gasket cuff 3070 extendsoutwardly from the longitudinal side edge 3049 of the backsheet 3032 inthe crotch region 3040. Therefore, the outer longitudinal edge 3084 ofthe gasket cuff 3070 defines the longitudinal side edge 3022 of thediaper 3020. Since the ear panel 3048 is formed by an integral materialof the backsheet 3032, the gasket cuff 3070 is formed by folding thelateral outer portion 3060 of the barrier leg cuff 3020, which willlater become the distal flap of the side flap, before the chassis 3054being integral with the ear panel 3048 and the barrier leg cuff 3052having the gasket cuff 3070 are joined to each other (i.e., before theear panel and the gasket cuff are joined to each other) such that theear panel 3048 would not be an obstacle to form the gasket cuff 3070.

The embodiment shown in FIGS. 22 and 23 is a so-called taped diaperhaving the fastening tape 3039 to form the closure of the diaper.Instead of having the fastening tape 3039, the longitudinal side edgesof the ear panels 3048 at the front waist region and the ear panels 3048at the back waist region may be joined by a seam such that the diaperforms a so-called pull-on diaper having one waist opening and two legopenings.

Although particular embodiments of the present invention have beenillustrated and described, it would be apparent to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit of the present invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A disposable absorbent article having an inner surface, an outersurface, a crotch region, longitudinal side edges and lateral end edges,and comprising a liquid pervious topsheet, a liquid imperviousbacksheet, an absorbent core disposed therebetween, and a side flapextending laterally outwardly from the absorbent core and having aproximal flap and a distal flap, the absorbent article furthercomprising an elasticized outer leg cuff disposed adjacent to thelongitudinal side edge in the crotch region and having a base and agasket cuff supported by the base at a joint of the base to the gasketcuff, the gasket cuff being provided with an elastic material and havingan inner cuff extending laterally inwardly from the joint and an outercuff extending laterally outwardly from the joint, wherein the basecomprises the proximal flap, the gasket cuff comprises the distal flapand is formed by folding the distal flap at least twice laterallyinwardly toward the longitudinal centerline of the absorbent article,and the gasket cuff and the base are joined at the joint positionedbetween the inner cuff and the outer cuff.
 2. The disposable absorbentarticle of claim 1 wherein the proximal flap and the distal flap arefanned from an integral material.
 3. The disposable absorbent article ofclaim 1 wherein the elasticized outer leg cuff is a generally T-shapedcuff.
 4. The disposable absorbent article of claim 1 wherein theelasticized outer leg cuff has an outer longitudinal edge and the outerlongitudinal edge of the elasticized outer leg cuff defines thelongitudinal side edge of the absorbent article.
 5. The disposableabsorbent article of claim 1 wherein the side flap is integrally formedwith an extension of an element constructing the absorbent article. 6.The disposable absorbent article of claim 5 wherein the side flap isintegrally formed with an extension of the topsheet.
 7. The disposableabsorbent article of claim 5 wherein the side flap is integrally formedwith an extension of the backsheet.
 8. The disposable absorbent articleof claim 5 wherein the disposable absorbent article comprises a barrierleg cuff, wherein the side flap is integrally formed with an extensionof the barrier leg cuff.
 9. The disposable absorbent article of claim 5wherein the disposable absorbent article comprises an outer nonwovencovering the backsheet, wherein the side flap is integrally formed withan extension of the outer nonwoven.
 10. The disposable absorbent articleof claim 1 wherein the disposable absorbent article has an ear panelextending laterally outwardly from the absorbent core, and the gasketcuff is formed by folding the distal flap before the ear panel and thegasket cuff are joined to each other.